Instrument panel with passenger airbag

Abstract

An instrument panel includes a substrate having an outer surface and an inner surface, a covering, a foam layer between the outer surface and the covering, and a chute elongated to an end. The end is attached to the inner surface. The end includes a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer.

What is claimed is: 
     
       1. An instrument panel comprising:
 a substrate having an outer surface and an inner surface; 
 a covering; 
 a foam layer between the outer surface and the covering; and 
 a chute elongated to an end, the end attached to the inner surface, the end including a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer; 
 wherein the chute is welded to the substrate. 
 
     
     
       2. The instrument panel of  claim 1 , further comprising a housing including the chute and a door, the door at least partially covering the end of the chute and being adjacent the substrate. 
     
     
       3. The instrument panel of  claim 2 , wherein the housing includes a hinge connecting the door to the end of the chute. 
     
     
       4. The instrument panel of  claim 3 , wherein the protrusion and the hinge in combination are elongated along substantially all the perimeter of the end of the chute. 
     
     
       5. The instrument panel of  claim 3 , wherein the housing is a single piece. 
     
     
       6. The instrument panel of  claim 5 , wherein the housing includes a flange extending outward from the chute. 
     
     
       7. The instrument panel of  claim 6 , wherein the door and the flange are attached to the substrate. 
     
     
       8. The instrument panel of  claim 7 , wherein the door and the flange are welded to the substrate. 
     
     
       9. The instrument panel of  claim 3 , wherein the hinge has an S-shaped cross-section. 
     
     
       10. The instrument panel of  claim 3 , wherein the substrate includes a slot elongated along the perimeter of the end of the chute away from the hinge. 
     
     
       11. The instrument panel of  claim 10 , wherein the slot is shaped to receive the protrusion. 
     
     
       12. The instrument panel of  claim 2 , wherein the door is attached to the substrate. 
     
     
       13. The instrument panel of  claim 1 , wherein the protrusion has a constant cross-section along the perimeter of the end of the chute. 
     
     
       14. The instrument panel of  claim 13 , wherein the cross-section of the protrusion is wedge-shaped. 
     
     
       15. The instrument panel of  claim 14 , wherein the wedge-shape of the cross-section of the protrusion has an angle less than 45°. 
     
     
       16. The instrument panel of  claim 1 , further comprising an airbag disposed in the chute. 
     
     
       17. An instrument panel comprising:
 a substrate having an outer surface and an inner surface; 
 a covering; 
 a foam layer between the outer surface and the covering; 
 a chute elongated to an end, the end attached to the inner surface, the end including a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer; and 
 a housing including the chute and a door, the door at least partially covering the end of the chute and being adjacent the substrate; 
 wherein the housing includes a hinge connecting the door to the end of the chute; and 
 the hinge has an S-shaped cross-section. 
 
     
     
       18. An instrument panel comprising:
 a substrate having an outer surface and an inner surface; 
 a covering; 
 a foam layer between the outer surface and the covering; 
 a chute elongated to an end, the end attached to the inner surface, the end including a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer; and 
 a housing including the chute and a door, the door at least partially covering the end of the chute and being adjacent the substrate; 
 wherein the housing includes a hinge connecting the door to the end of the chute; 
 the housing is a single piece; 
 the housing includes a flange extending outward from the chute; and 
 the door and the flange are attached and welded to the substrate.